Vacuum Device Including Selectively Activated, Secondary Vacuum Source and Floor Cleaning Machine Utilizing the Vacuum Device

ABSTRACT

A floor cleaning machine ( 100 ) utilizing a vacuum device ( 10 ) includes a tank ( 20 ) having an inlet ( 22 ) through which dirt, debris, or soiled solution is pulled along with air into the tank ( 20 ). The tank ( 20 ) further includes first and second air outlets ( 24, 30 ) both in communication with the tank ( 20 ). Air in the tank ( 20 ) is drawable out through the first air outlet ( 24 ) and selectively drawable out through the second air outlet ( 30 ). A check valve ( 40 ) is mounted in the second air outlet ( 30 ) preventing airflow from the second air outlet ( 30 ) to the tank ( 20 ). The check valve ( 40 ) allows the air in the tank ( 20 ) to be drawn out through the second air outlet ( 30 ) when more vacuum power is needed. The check valve ( 40 ) prevents airflow from the second air outlet ( 30 ) to the tank ( 20 ) when air is not being drawn out of the second air outlet ( 30 ) and while air in the tank ( 20 ) is being drawn out through the first air outlet ( 24 ) when less vacuum power is needed. A vacuum tool ( 104 ) in communication with the inlet ( 22 ) removes previously applied solution from the floor surface which is agitated by an agitator ( 112 ).

BACKGROUND OF THE INVENTION

The present invention relates to a vacuum device and, more particularly, to a vacuum device including selectively activated, secondary vacuum source. The present invention also relates to a floor cleaning machine utilizing the vacuum device.

Various floor cleaning machines such as tank vacuums, carpet extractors, floor surface scrubbers, etc. are used for removing different types of dirt, debris, or soiled solution from a variety of surfaces ranging from smooth hard surfaces such as vinyl tile, to rough surfaces such as ceramic tile or textured concrete, and to carpeted surfaces of various depths and textures. A typical floor cleaning machine generally includes a collection tank and a vacuum motor to produce a vacuum within the collection tank for pulling air along with dirt, debris, or soiled solution through a flexible hose or a rigid passage into the collection tank where the dirt, debris, or dirty solution is accumulated. Some combinations of dirt, debris, or soiled solution and floor surfaces are much harder to clean than others. As an example, more vacuum power is required for carpeted floor surfaces than for hard floor surfaces. As a result, the vacuum power required to draw the dirt, debris, or soiled solution off the floor and into the collection tank varies greatly depending on conditions. Further, multi-task floor cleaning machines have been introduced which are intended to be utilized for several different types of floor surfaces. One or more additional vacuum motors are sometimes utilized to achieve a higher amount of vacuum power. If more vacuum motors are activated, besides increased noise, the operating cost is increased due to increased power consumption that also results in, in the case of battery powered equipment, reduced battery life. However, turning off one or more additional vacuum motors when vacuum power requirements are less is not possible as air will be drawn through the inoperative vacuum motor and thereby reducing the vacuum to an unacceptable level.

Therefore, a need exists for a vacuum device that enables the machine operator to only use the amount of power necessary to clean various soil and floor combinations according to the vacuum power needs and without loss of vacuum.

BRIEF SUMMARY OF THE INVENTION

The present invention solves this need and other problems in the field of vacuum devices by providing, in a preferred form, a tank having an inlet through which dirt, debris, or soiled solution to be removed from a floor or the like is pulled along with air into the tank. The tank further includes a first air outlet and a second air outlet both in communication with the tank. In the most preferred form, the second air outlet includes an air passage having an inner, smaller section and an outer, larger section having an inner diameter greater than that of the inner, smaller section. The inner, smaller section has an inner end in direct communication with the tank and is intermediate the outer, larger section and the tank. A check valve is mounted in the outer, larger section. In the most preferred form, the check valve includes a ball movably received in the outer, larger section and has a diameter greater than the diameter of the inner, smaller section and smaller than the inner diameter of the outer, larger section. A first vacuum source in the preferred form of an air mover is mounted in the first air outlet for drawing air in the tank out of the first air outlet. A second vacuum source in the preferred form of an air mover is mounted in the outer, larger section of the second air outlet for drawing air in the tank out of the second air outlet.

When a smaller amount of vacuum power is needed, the first air mover is activated for drawing air in the tank out of the first air outlet while the second air mover is inoperative. Dirt, debris, and/or soiled solution are pulled along with air into and accumulated in the tank under the action of the vacuum created by the first air mover. Meanwhile, the vacuum created by the first air mover also draws air in the inner, smaller section of the second air outlet into the tank and draws air outside the tank into the outer, larger section. Thus, the ball is moved to abut against the inner, smaller section and blocks the air passage of the second air outlet, avoiding loss of vacuum through the second air mover.

When more vacuum power is needed, the second air mover is activated to draw air out of the tank through the second air outlet while the first air mover is still operative to also draw air out of the tank through the first air outlet. When the second air mover is operative, air in the tank is drawn into the smaller, inner section and pushes the ball away from the smaller, inner section. The air passage of the second air outlet is, thus, not blocked to allow more air to be drawn out of the tank under the action of the second air mover to provide more vacuum power.

The tank can be utilized with a floor cleaning machine that applies solution to a floor surface to be cleaned and a vacuum tool in communication with the inlet of the tank for removing soiled solution from the floor surface for transference into the tank. In one most preferred form, the vacuum tool is a vacuum shoe for cleaning a carpet on a floor surface, and the floor cleaning machine further includes an agitator for agitating the solution on the carpet. Dirty solution, dirt, debris, etc. are then sucked into the tank via the vacuum shoe by the vacuum device according to the preferred teachings of the present invention according to the nature of soil and carpet combination while the floor cleaning machine is moved over the carpet. A most preferred application of the vacuum device is in a floor cleaning machine intended to be used for different types of floor surfaces such as both carpeted and hard floor surfaces.

The present invention will become clearer in light of the following detailed description of an illustrative embodiment of this invention described in connection with the drawings.

DESCRIPTION OF THE DRAWINGS

The illustrative embodiment may best be described by reference to the accompanying drawings where:

FIG. 1 shows an exploded, perspective view of a floor cleaning machine utilizing a vacuum device according to the preferred teachings of the present invention with portions of the floor cleaning machine cut away to show an interior thereof.

FIG. 2 shows a partial, sectional view of the vacuum device of FIG. 1 with both first and second air movers operative.

FIG. 3 shows a partial, sectional view of the vacuum device of FIG. 1 with the first air mover operative and with the second air mover inoperative.

All figures are drawn for ease of explanation of the basic teachings of the present invention only; the extensions of the Figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements will likewise be within the skill of the art after the following teachings of the present invention have been read and understood.

Where used in the various figures of the drawings, the same numerals designate the same or similar parts. Furthermore, when the terms “first”, “second”, “end”, “section”, “outward”, “inward”, and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A vacuum device according to the preferred teachings of the present invention is shown in the drawings and generally designated 10. Vacuum device 10 can be utilized to clean various combinations of dirt, debris, soiled solution or other substances to be removed from a variety of surfaces including but not limited to smooth hard surfaces such as vinyl tile, rough surfaces such as ceramic tile or textured concrete, and carpeted surfaces of various depths and textures. In the preferred form shown, vacuum device 10 is utilized in a floor cleaning machine 100.

According to the preferred form shown, floor cleaning machine 100 generally includes a vacuum tool 104 and a suction tube 106 having a lower end 110 coupled with vacuum tool 104 and an upper end 108 in communication with vacuum device 10. Floor cleaning machine 100 further includes an agitator 112 shown in the form of a cylindrical brush rotated about a horizontal axis parallel to the floor surface for agitating the floor surface, thereby improving debris pick-up of vacuum tool 104. Furthermore, floor cleaning machine 100 includes wheels 102 to allow mobility, batteries (not shown) for powering floor cleaning machine 100, and, optionally, a drive motor 114 for driving wheels 102. Further, in the case of a walk-behind unit, floor cleaning machine 100 includes a handle 118 for an operator to direct floor cleaning machine 100 from behind. Further, floor cleaning machine 100 of the preferred form shown includes a clean solution tank 116 holding clean solution to be applied to a floor surface.

Vacuum tool 104 can be in a form according to the nature of the floor surface to be cleaned. Specifically, vacuum tool 104 can be in the form of a vacuum shoe for soft floors (carpet extractors) or in the form of a squeegee for hard floors for use with hard floor surface cleaning machines (or floor scrubbers). However, vacuum tool 104 can be multifunctional for hard or soft floors or combinations of hard and soft floors. Likewise, vacuum tool 104 can be of a specific type for use on a hard floor and can be interchanged with a vacuum tool of another type for use on a soft floor according to needs such as but not limited to as disclosed in U.S. Pat. No. 5,455,982. Furthermore, floor cleaning machine 100 can include both types of vacuum tools 104, one of which is selected in response to the nature of the floor surface to be cleaned while the other is not functional such as but not limited to as disclosed in U.S. Patent Publication No. 20040074028. Furthermore, agitator 112 can be of other forms including but not limited to rotatable discs that are rotatable about vertical axes, brushes, teeth, or similar protrusions that are fixed or movable relative to a machine frame which is movable relative to the floor surface or the like. Further, floor cleaning machine 100 can have other arrangements or selections of features such as having vacuum tool 104 with a built-in agitator 112 and/or that does not include clean solution tank 116 or apply solution to the floor surface. Specifically, vacuum device 10 according to the teachings of the present invention can be utilized with floor cleaning machines 100 of various types and forms.

According to the preferred form shown, vacuum device 10 includes a tank 20 formed with an inlet 22, a first air outlet 24, and a second air outlet 30. Each of inlet 22 and first and second air outlets 24 and 30 is in communication with tank 20. In the most preferred form shown, inlet 22 of tank 20 is in communication with upper end 108 of suction tube 106 of floor cleaning machine 100. A shut-off check valve can be mounted in inlet 22 for stopping flow when tank 20 is full. Tank 20 further includes a drain opening to empty collected solution. First and second air outlets 24 and 30 can be integrally formed in tank 20 by roto or blow molding. Other methods for forming first and second air outlets 24 and 30 in tank 20 would be within the skill of the art.

In the most preferred form shown, first air outlet 24 and second air outlet 30 are in independent communication with tank 20. Second air outlet 30 includes an air passage 36 having an inner, smaller section 32 and an outer, larger section 34. Outer, larger section 34 has an inner diameter greater than that of inner, smaller section 32. Inner, smaller section 32 has an inner end in direct communication with tank 20 and is intermediate outer, larger section 34 and tank 20.

In the preferred form shown, a first vacuum source in the preferred form of an air mover 50 is mounted in first air outlet 24 for drawing air in tank 20 out through first air outlet 24, producing a vacuum in tank 20. First air mover 50 further includes a plurality of exhaust ports 54 in communication with first air outlet 24 and the outside. In the most preferred form shown, first air mover 50 is mounted in an outer end of first air outlet 24 and is in the form of a vacuum motor having a fan that can be rotated to draw air out of tank 20 through first air outlet 24. First air mover 50 can be of any desired form as conventional including but not limited to of a commercially available type, and the fan of first air mover 50 can be a purchased part.

A check valve 40 is mounted in outer, larger section 34 of second air outlet 30. In the most preferred form shown, check valve 40 includes a ball 42 movably received in outer, larger section 34 and has a diameter greater than the diameter of inner, smaller section 32 and smaller than the inner diameter of outer, larger section 34.

Also mounted in outer, larger section 34 of second air outlet 30 is a second vacuum source in the preferred form of an air mover 60 that includes an internal air passageway 62 in communication with outer, larger section 34. Second air mover 60 further includes a plurality of exhaust ports 64 in communication with internal air passageway 62 and the outside. In the most preferred form shown, second air mover 60 is in the form of a vacuum motor having a fan that can be rotated to draw air out of tank 20 through second air outlet 30. Second air mover 60 can be of any desired form as conventional including but not limited to of a commercially available type, and the fan of second air mover 60 can be a purchased part.

In the form shown, a lid 66 can be provided in a sealing relationship with the tank 20 to enclose and provide fluid communication between the upper ends of air outlets 24 and 30 and an upper access opening of the tank 20. Switches for controlling on/off of first and second air movers 50 and 60 can be mounted on a console or the like for the operator to control desired vacuum power. The console may further include other controls for stopping solution flow to the carpet or floor surface and for controlling on/off of drive motor 114, agitator 112, etc.

Now that the basic construction of vacuum device 10 of the preferred teachings of the present invention has been explained, the operation and some of the advantages of vacuum device 10 and floor cleaning machine 100 utilizing the vacuum device 10 can be set forth and appreciated. Drive motor 114 is activated to drive wheels 102 for moving floor cleaning machine 100 over a floor surface. Clean solution in clean solution tank 116 is applied to the floor surface. The solution is agitated by agitator 112 that moves over the floor surface together with floor cleaning machine 100 to improve debris pick-up. Dirty solution is vacuumed up together with dirt, debris, etc. via vacuum tool 104 and suction tube 106 into tank 20 by the vacuum power provided by vacuum device 10 while floor cleaning machine 100 is moved over the carpet.

For producing a small amount of vacuum power such as in response to a nature of a light soil and hard floor surface combination, first air mover 50 is activated by its corresponding switch on the console to rotate its fan to draw air out of tank 20 through first air outlet 24 while second air mover 60 is inoperative. Dirt, debris, and soiled solution on the floor surface are pulled along with air into and accumulated in tank 20 via inlet 22 under the action of vacuum created by first air mover 50. The vacuum created by first air mover 50 also draws air in inner, smaller section 32 of second air outlet 30 into tank 20 and draws air outside tank 20 into outer, larger section 34 through exhaust ports 64 and internal air passageway 62 of second air mover 60. Thus, ball 42 is drawn to move toward and abut against inner, smaller section 32 of second air outlet 30. As a result, air passage 36 of second air outlet 30 is blocked by ball 42 under the action of the vacuum created by first air mover 50 while second air mover 60 is inoperative. Loss of vacuum through second air mover 60 due to air leakage is, thus, avoided.

When more vacuum power is needed such as due to a heavier soil and soft floor surface combination, second air mover 60 is activated by its corresponding switch on the console to rotate its fan to draw air out of tank 20 through second air outlet 30 while first air mover 50 is still operative to also draw air out of tank 20 through first air outlet 24. When second air mover 60 is operative, air in tank 20 is drawn into smaller, inner section 32 and pushes ball 42 away from smaller, inner section 32. Air passage 36 of second air outlet 30 is, thus, not blocked such that air can be drawn out through outer, larger section 34 of second air outlet 30 and then internal air passageway 62 and exhaust ports 64 of second air mover 60 after flowing around ball 42. More air is drawn out of tank 20 under the action of second air mover 60 to provide more vacuum power. It should be appreciated that it may be desirable for first air mover 50 to be inoperative when second air mover 60 is initially operative to insure that ball 42 is pushed away from smaller, inner section 32. Since first air outlet 24 in the preferred form does not include a check valve 40, first air mover 50 must be operative at all times when vacuum power is desired to prevent loss of vacuum therethrough.

Now that the basic teachings of the present invention have been explained, many extensions and variations will be obvious to one having ordinary skill in the art. For example, tank 20 can have any desired shape or can be any object defining a space for collection of dirt, debris, or soiled solution. A filter bag or filter system can be provided in air outlets 24 and 30 to prevent dirt, debris, or soiled solution from leaving tank 20.

In the most preferred form shown, first and second air outlets 24 and 30 are integrally formed as part of tank 20 and are believed to produce synergistic results. However, tank 20 can include first and second air outlets 24 and 30 which are separately formed from tank 20 but in communication with tank 20. Further, although shown as being in separate communication with tank 20 in the form shown, first and second air outlets 24 and 30, whether integrally formed or separately formed with tank 20, can be in communication with each other such as by a substantially Y-shaped or similarly shaped passageway, can be in communication with a secondary chamber which in turn is in communication with tank 20, or the like, without adversely affecting operation of check valve 40 according to the preferred teachings of the present invention. Vacuum device 10 according to the preferred teachings of the present invention may include as many additional air movers 60 each with a check valve 40 as desired to increase the vacuum power, and selective operations of these additional second air movers 60 provide required vacuum power without incurring air leakage.

Ball 42 can be of any desired form. Furthermore, ball 42 can be replaced with a flexible membrane or a shuttle that is pushed by inward airflow toward tank 20 to a position blocking air passage 36 of second air outlet 30 when first air mover 50 is operative and second air mover 60 is inoperative and that is pushed by outward airflow away from tank 20 to another position not blocking air passage 36 of second air outlet 30 when first and second air movers 50 and 60 are both operative. Whenever necessary, the structure of second air outlet 30 can be modified according to the replacement of ball 42, and such modifications would be within the skill of the art.

Vacuum device 10 according to the preferred teachings of the present invention can work as a device for producing desired vacuum power for various purposes, including but not limited to surface cleaning, at the minimized costs without loss of vacuum resulting from air leakage.

Vacuum device 10 according to the preferred teachings of the present invention enables the operator to vary the amount of vacuum power in response to various soil and floor combinations by selectively operating one or more additional air movers without leakage of air during operation. Operational noise is reduced, less energy is consumed, and battery life is prolonged if first and second air movers 50 and 60 are battery powered. Furthermore, vacuum device 10 according to the preferred teachings of the present invention is simple in structure and, thus, has low costs.

Thus since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. 

1. A floor cleaning machine comprising, in combination: a solution supplier for applying solution to a floor surface to be cleaned; a tank including an inlet, a first air outlet, and a second air outlet, with each of the inlet and the first and second air outlets being in communication with the tank; a check valve mounted in the second air outlet preventing airflow from the second air outlet to the tank, with the check valve allowing the air in the tank to be drawn out through the second air outlet, and with the check valve preventing airflow from the second air outlet to the tank when air is not being drawn out of the second air outlet and while air in the tank is being drawn out through the first air outlet; and a vacuum tool including a first end in communication with the inlet of the tank and a second end for removing the solution from the floor surface for transference into the tank, with air in the tank being drawable out through the first air outlet for providing a vacuum power for sucking the solution from the floor surface through the vacuum tool and the inlet into the tank and selectively drawable out through the second air outlet for providing an additional vacuum power for sucking the solution from the floor surface through the vacuum tool and the inlet into the tank.
 2. The floor cleaning machine as claimed in claim 1, further comprising, in combination: an agitator for agitating the solution on the floor surface before the vacuum tool removes the solution from the floor surface.
 3. The floor cleaning machine as claimed in claim 1, with the vacuum tool being a vacuum shoe for carpeting.
 4. The floor cleaning machine as claimed in claim 1, with the check valve being moveable between an open position allowing airflow between the tank and the second air outlet and a closed position preventing airflow between the tank and the second air outlet, and with the check valve being moved to the closed position under action of a vacuum created by drawing air through the first air outlet.
 5. The floor cleaning machine as claimed in claim 4, with the second air outlet including an air passage having an inner, smaller section in communication with the tank and an outer, larger section, with the inner, smaller section being intermediate the tank and the outer, larger section, with the inner, smaller section having a diameter, with the outer, larger section having an inner diameter larger than the diameter of the inner, smaller section, with the check valve further including a ball movably received in the outer, larger section and having a diameter greater than the diameter of the inner, smaller section and smaller than the inner diameter of the outer, larger section, with the ball being moved toward and blocking the inner, smaller section under the action of the vacuum created by drawing air through the first air outlet when air is not being drawn out of the second air outlet, and with the ball being moved away from the inner, smaller section by the air drawn through the second air outlet and not blocking the inner, smaller section when air is being drawn through the second air outlet.
 6. The floor cleaning machine as claimed in claim 5, with air being drawn through the second air outlet by an air mover received in the outer, larger section of the air passage, with the air mover including an internal air passageway in communication with the outer, larger section, with the air in the tank being drawn out through the inner, smaller section, the outer, larger section, and the internal air passageway and pushing the ball away from the inner, smaller section when the air mover operates, and with air outside the tank flowing into the outer, larger section through the internal air passageway to move the ball to press against and block the inner, smaller section when the air mover is inoperative and air is being drawn out of the tank through the first air outlet.
 7. The floor cleaning machine as claimed in claim 6, with the air mover being a fan, and with the second end of the vacuum tool engaging with the floor surface for restricting airflow into the vacuum tool between the vacuum tool and the floor surface.
 8. The floor cleaning machine as claimed in claim 5, with the first air outlet and the second air outlet being integrally formed and independently communicating with the tank.
 9. The floor cleaning machine as claimed in claim 3, further comprising, in combination: an air mover mounted in the first air outlet for drawing air in the tank out the first air outlet.
 10. The floor cleaning machine as claimed in claim 9, with the air mover being a fan.
 11. A vacuum device comprising, in combination: a tank including an inlet, a first air outlet, and a second air outlet, with each of the inlet and the first and second air outlets being in communication with the tank, and with air in the tank being drawable out through the first air outlet and selectively drawable out through the second air outlet; and a check valve mounted in the second air outlet preventing airflow from the second air outlet to the tank, with the check valve allowing the air in the tank to be drawn out through the second air outlet, and with the check valve preventing airflow from the second air outlet to the tank when air is not being drawn out of the second air outlet and while air in the tank is being drawn out through the first air outlet.
 12. The vacuum device as claimed in claim 11, with the check valve being moveable between an open position allowing airflow between the tank and the second air outlet and a closed position preventing airflow between the tank and the second air outlet, and with the check valve being moved to the closed position under action of a vacuum created by drawing air through the first air outlet.
 13. The vacuum device as claimed in claim 12, with the second air outlet including an air passage having an inner, smaller section in communication with the tank and an outer, larger section, with the inner, smaller section being intermediate the tank and the outer, larger section, with the inner, smaller section having a diameter, with the outer, larger section having an inner diameter larger than the diameter of the inner, smaller section, with the check valve further including a ball movably received in the outer, larger section and having a diameter greater than the diameter of the inner, smaller section and smaller than the inner diameter of the outer, larger section, with the ball being moved toward and blocking the inner, smaller section under the action of the vacuum created by drawing air through the first air outlet when air is not being drawn out of the second air outlet, and with the ball being moved away from the inner, smaller section by the air drawn through the second air outlet and not blocking the inner, smaller section when air is being drawn through the second air outlet.
 14. The vacuum device as claimed in claim 13, with air being drawn through the second air outlet by an air mover received in the outer, larger section of the air passage, with the air mover including an internal air passageway in communication with the outer, larger section, with the air in the tank being drawn out through the inner, smaller section, the outer, larger section, and the internal air passageway and pushing the ball away from the inner, smaller section when air mover operates, and with air outside the tank flowing into the outer, larger section through the internal air passageway to move the ball to press against and block the inner, smaller section when the air mover is inoperative and air is being drawn out of the tank through the first air outlet.
 15. The vacuum device as claimed in claim 14, with the air mover being a fan.
 16. The vacuum device as claimed in claim 13, with the first air outlet and the second air outlet being integrally formed and independently communicating with the tank.
 17. The vacuum device as claimed in claim 11, further comprising, in combination: a vacuum tool including a first end in communication with the inlet of the tank and a second end for removing the solution from the floor surface for transference into the tank, with the second end of the vacuum tool engaging with the floor surface for restricting airflow into the vacuum tool between the vacuum tool and the floor surface.
 18. The vacuum device as claimed in claim 17, further comprising, in combination: an agitator for agitating the floor surface, with the agitator cooperating with the vacuum tool to agitate the floor surface before the solution is removed from the floor surface through the vacuum tool.
 19. The vacuum device as claimed in claim 11, further comprising, in combination: an air mover mounted in the first air outlet for drawing air in the tank out the first air outlet.
 20. The vacuum device as claimed in claim 19, with the air mover being a fan. 